The Challenge

Our client’s facility operates 32 maintenance positions on rotating shifts to maintain 24/7 equipment coverage. With the maintenance team and the planning, scheduling and supervisory leadership temporarily away from operations, the clock started ticking. 

At the time, their maintenance backlog had grown to approximately six weeks, with roughly 200 hours of emergency work outstanding across the facility’s ammonia refrigeration unit, brewery cellar and can manufacturing lines. With 12 100,000-gallon tanks of product in the cellar, millions of dollars worth of product would be lost if the refrigeration system failed. Our client needed a partner who could step in quickly, take ownership of the program and maintain full operational continuity.

Services Delivered

Our Approach

Our team of technicians reviewed the client’s full maintenance backlog and assessed their immediate operational needs. Rather than matching the facility’s existing headcount, we adjusted to fit the work required and deployed 10 technicians to cover a program built around 32 positions.

With maintenance leadership unavailable, our technicians stepped into planning, scheduling and supervisory roles from day one to:

• Learn the client’s SAP CMMS on-site in a compressed timeframe to ensure uninterrupted operations
• Manage all scheduling, materials and manpower with Cornerstone’s in-house support systems
• Order materials through our in-house systems when information was unavailable
• Use our scoping methods to identify the correct materials for rebuilds
• Provide millwright labor support
• Serve as the turnkey service provider for any of the facility’s needs

From intake to execution, we operated as a full program owner and helped decrease our client’s maintenance backlog by 90%.